TW202140239A - Composite rebar with post-grinding surface treatment - Google Patents

Abstract

A composite rebar having ridges formed therein by grinding is buffed and/or coated to reduce the surface roughness caused by fibers extending from the rebar.

Description

Composite ribs with surface treatment after grinding

Cross-reference of related applications This application claims the priority and all rights and interests of U.S. Provisional Patent Application No. 62/990,465 filed on March 17, 2020, and the entire disclosure is incorporated herein by reference in its entirety.

The present invention generally relates to reinforcing materials, and more specifically, to composite ribs that have been surface-treated after grinding.

Composite bars are known substitutes for steel bars. Reinforcement is the abbreviation of stiffener, used as a tension element for stiffening concrete to strengthen and make the concrete compressive. Composite ribs are formed by fibers (such as glass, carbon) bonded together by a resin matrix (ie, adhesive). The binder can be a thermosetting or thermoplastic resin. Since the ribs usually have a constant cross-section, pultrusion is a very suitable process for forming the fiber reinforced plastic/polymer (FRP) ribs. Just like steel bars, it is known to introduce surface topography into composite bars to provide anchor points between the composite bars and concrete. These anchor points ensure a strong mechanical interlock between the composite bar and the concrete.

Traditionally, these anchor points are formed on the composite rib by wrapping additional materials (such as fiber strands) around the outer surface of the fiber rod, such as shown in U.S. Patent No. 4,620,401 (the entire disclosure of which is incorporated herein by reference). The method is incorporated into this article). As shown in Figure 1, this procedure 100 involves forming a composite rod (step 102), and then applying the wrap to the rod to create raised ribs (step 104). Any pre-forming process is represented by "A" in Figure 1, and any post-coating process is represented by "B" in Figure 1. The resulting composite rib 200 is shown in FIG. 2. The composite rib 200 includes a composite body 202 having a relatively uniform thickness T. Since the composite body 202 is a substantially cylindrical member, the thickness T of the composite body 202 is defined by the diameter of the cylindrical member. The spiral wrap 204 is formed or otherwise disposed on the outer surface of the composite body 202. The spiral wrap 204 forms a plurality of raised ribs 206 which are spaced apart from each other and extend beyond the thickness T of the composite body 202.

In view of the above, there is still an unsatisfied requirement in terms of the procedure for forming anchor points on the composite ribs, that is, there is no need to interface additional materials with a pultruded rod.

In view of the foregoing, the broad concept of the present invention is to study and cover a composite bar with a plurality of anchor points, which are formed in the composite bar by removing material from the composite bar. More specifically, a grinding operation is used to remove parts of the composite rib to produce raised portions, which are separated by the removed portions. Taking into account any fibers exposed during the grinding operation, the composite ribs are then polished and/or coated.

In an exemplary embodiment, a method of forming a composite rib is disclosed. The method includes forming a rod by combining a plurality of relatively parallel fibers with a resin, and the resin is cured to solidify the rod; and grinding the rod to remove a part of the fiber and the resin.

In some exemplary embodiments, the fibers are glass fibers.

In some exemplary embodiments, the resin is a vinyl ester resin. In some exemplary embodiments, the resin is an epoxy resin. In some exemplary embodiments, the resin is a resin that complies with ASTM D 7957. In some exemplary embodiments, the resin is a resin that meets Canadian Standard S807.

In some exemplary embodiments, the grinding system forms a continuous spiral groove in the rod. In some exemplary embodiments, the spiral groove has a width in the range of .200 inches to .260 inches. In some exemplary embodiments, the spiral groove has a width ranging from .240 inches to .260 inches. In some exemplary embodiments, the spiral groove has a depth in the range of 0.007 inches to 0.020 inches. In some exemplary embodiments, the spiral groove has a depth in the range of 0.008 inches to 0.016 inches. In some exemplary embodiments, the spiral groove has a pitch in the range of .380 inches to .420 inches (that is, the distance traveled along the longitudinal axis of the rod when the groove completes one revolution (360°) ).

In some exemplary embodiments, the method further includes polishing at least one surface of the spiral groove.

In some exemplary embodiments, the method further includes coating at least one surface of the spiral groove.

In some exemplary embodiments, the method further includes polishing at least one surface of the spiral groove and then coating at least one surface of the spiral groove after the polishing.

In an exemplary implementation aspect, a composite rib is disclosed. The composite rib includes a rod, the rod includes a plurality of relatively parallel fibers joined by a cured resin, and a continuous spiral groove is formed along the length of the rod.

In some exemplary embodiments, the fibers are glass fibers.

In some exemplary embodiments, the resin is a vinyl ester resin. In some exemplary embodiments, the resin is an epoxy resin. In some exemplary embodiments, the resin is a resin that complies with ASTM D 7957. In some exemplary embodiments, the resin is a resin that meets Canadian Standard S807.

In some exemplary embodiments, the spiral groove has a width in the range of .200 inches to .260 inches. In some exemplary embodiments, the spiral groove has a width ranging from .240 inches to .260 inches. In some exemplary embodiments, the spiral groove has a depth in the range of 0.007 inches to 0.020 inches. In some exemplary embodiments, the spiral groove has a depth in the range of 0.008 inches to 0.016 inches. In some exemplary embodiments, the spiral groove has a pitch in the range of .380 inches to .420 inches (that is, the distance traveled along the longitudinal axis of the rod when the groove completes one revolution (360°) ).

In some exemplary embodiments, the spiral groove has a polished surface.

In some exemplary embodiments, the spiral groove has a coated surface.

In some exemplary embodiments, the spiral groove has a polished and coated surface.

Many other aspects, advantages and/or features of the broad concept of the invention will become more apparent from the detailed description of the exemplary embodiments herein, the scope of patent application, and the accompanying drawings attached to the text below.

These broad inventive concepts can be interpreted as many different forms of implementation, and under the understanding that the content of this disclosure is only regarded as an illustration of these broad inventive concepts, the specific implementation is shown in the diagram and will be detailed in In this article. Therefore, these broad inventive concepts are not intended to be limited to the specific implementation aspects described herein.

As pointed out above, these broad inventive concepts are intensively researched and cover a composite rib with multiple anchor points, which are formed in the composite rib by removing material from the composite rib. For example, the pultruded composite rod is formed by grinding to form protrusions (i.e., ribs), thereby forming anchor points on the rod. Taking into account any fibers exposed during the grinding operation, the rod is then polished and/or coated.

An improved composite rib 400 is proposed, as shown in FIG. 4. An exemplary method 300 of forming the composite rib 400 will be described with reference to FIG. 3. Method 300 involves forming a composite rod (step 302), and then grinding the rod to remove material from it to form ribs (step 304). Any pre-forming process is represented by "A" in Figure 3, and any post-grinding process is represented by "B" in Figure 3.

In step 302, the composite rod can be formed by any suitable method, such as by pultrusion. In some exemplary implementation aspects, step 302 is the same as step 102. In some exemplary embodiments, the composite rod system is formed of glass fibers held together by an adhesive. Any suitable adhesive can be used. In some exemplary embodiments, the adhesive is a vinyl ester resin. In some exemplary embodiments, the adhesive is an epoxy resin. In some exemplary embodiments, the adhesive is a resin conforming to ASTM D 7957. In some exemplary embodiments, the adhesive is a resin that meets Canadian Standard S807.

In step 304, the composite rod is subjected to an operation such as mechanical grinding, which removes a part of the composite material from the rod. In the case of mechanical grinding, a continuous (oblique) channel is formed in the composite rod. In some exemplary embodiments, the grinding device is fixed while the composite rod moves relative to it. In some exemplary embodiments, the composite rod is fixed while the grinding device moves relative to it.

The resulting composite rib 400 includes a composite body 402 having a relatively uniform thickness T. Since the composite body 402 is a substantially cylindrical member, the thickness T of the composite body 402 is defined by the diameter of the cylindrical member. When the composite body 402 is ground to remove material therefrom, a spiral channel 404 is formed therein. Therefore, the thickness T is no longer uniform along the length direction of the composite body 402. The spiral channel 404 creates a separated removed portion 406 and a remaining portion 408, which together form a plurality of anchor points in the composite rib 400. The removed part 406 is shaped into a width W and a depth D, as shown in FIG. 5. The remaining part 408 does not extend beyond the original (ie, before grinding) thickness T of the composite body 402.

In some exemplary embodiments, the width W is greater than the depth D. In some exemplary embodiments, the width W is less than the depth D. In some exemplary embodiments, the width W is equal to the depth D. In some exemplary embodiments, the width W is greater than the width W′ of the remaining portion 408. In some exemplary embodiments, the width W is less than the width W′. In some exemplary embodiments, the width W is equal to the width W′.

The removed portion 406 is formed by grinding the composite body 402 to a desired width W and a desired depth D, the width is also shown by the dashed line 410, and the depth is also shown by the dashed line 412. One consequence of this grinding procedure (step 304) is that some of the fibers constituting the composite body 402 are broken and/or protruding, which is shown graphically in FIG. In the cavity. It has been found that these protruding fibers make it difficult to handle the composite rib 400 product safely/comfortably.

Therefore, in an exemplary embodiment, a method 600 of forming an improved composite rib 700 is shown in FIG. 6. The method 600 involves forming the composite rod (step 302), grinding the rod to remove material therefrom to produce the ribs (step 304), and then polishing the parts of the rod where the material has been removed (step 610) . Any pre-formed processing is represented by "A" in Figure 6, and any post-polishing processing is represented by "B" in Figure 6.

In step 610, polishing can be performed in any suitable manner. In some exemplary embodiments, a fine abrasive material is used to polish the protrusion 414 extending beyond the line 410 to completely or significantly remove the protrusion 414 to form a polished surface 702, as shown in FIG. 7 . Examples of polishing techniques include (but are not limited to) the use of abrasive wheels, scrubbing pads, sanding devices, fiber brushes, or deburring sheets.

The measured surface roughness of the removed part 406 (or any related part thereof) after buffing is greatly reduced compared to the surface roughness of the removed part 406 before buffing.

In step 610, the composite rod is subjected to an operation such as mechanical buffing, which smoothes the part of the rod with outwardly protruding fibers. In the case of mechanical buffing, the buffing equipment usually travels along a continuous (oblique) channel formed by grinding the composite rod. In some exemplary embodiments, the polishing device is fixed while the composite rod moves relative to it. In some exemplary embodiments, the composite rod system is fixed while the polishing device moves relative to it.

A part of the resulting composite rib 700 with a polished surface 702 is shown in FIG. 7, which is a modified version of the detailed view of FIG. 5. Due to the polishing operation, the protrusion 414 (generated by the polishing operation) has been removed or otherwise reduced. In other words, the surface smoothness of the spiral channel 404 is increased by the polishing operation (that is, the polished surface 702), which makes the composite rib 700 safer/comfortable to handle.

In another exemplary embodiment, a method 800 of forming an improved composite rib 900 is shown in FIG. 8. Method 800 involves forming the composite rod (step 302), grinding the rod to remove material therefrom to produce the ribs (step 304), and then coating the portions of the rod with the removed material (step 810) . Any pre-formed processing is shown as "A" in Figure 8, and any post-coating processing is shown as "B" in Figure 8.

In step 810, the coating can be performed in any suitable manner. In some exemplary embodiments, a coating composition is applied to the protrusion 414 extending beyond the line 410 to completely or significantly cover the protrusion 414 and form a coated surface 902, as shown in FIG. 9. Any suitable coating composition that effectively covers the protruding portion 414 can be used, thereby providing a non-adhesive surface treatment that improves the handling of the composite rib 900.

The measured surface roughness of the removed part 406 (or any related part thereof) after buffing is greatly reduced compared to the surface roughness of the removed part 406 before buffing.

In step 810, the composite rod is subjected to an operation such as spraying, which covers the part of the rod with outwardly protruding fibers. In the case of spraying, the coating equipment can travel along a continuous (oblique) channel formed by grinding the composite rod. Other coating techniques such as curtain coating and vacuum coating can also be used. In some exemplary embodiments, the coating device is fixed while the composite rod moves relative to it. In some exemplary embodiments, the composite rod system is fixed while the coating device moves relative to it. In some exemplary embodiments, only the removed portion 406 (such as the spiral channel 404) or some portions thereof are coated. In some exemplary embodiments, the removed portion 406 (such as the spiral channel 404) and the remaining portion 408 are coated.

A part of the resulting composite rib 900 with the coated surface 902 is shown in FIG. 9, which is a modified version of the detailed view of FIG. 5. Generally, the coating will be applied to all surfaces of the composite rod (or at least all surfaces from which material has been removed), as shown in FIG. 9. Due to the coating operation, the protruding portion 414 (produced by the grinding operation) has been completely or significantly covered. In other words, the surface smoothness of the spiral channel 404 is increased by the coating operation (ie, the coated surface 902), which makes the composite rib 900 safer/comfortable to handle.

In yet another exemplary embodiment, a method 1000 of forming an improved composite rib 1100 is shown in FIG. 10. The method 1000 involves forming a composite rod (step 302), grinding the rod to remove material therefrom to produce the ribs (step 304), and then polishing the parts of the rod where the material has been removed (step 610), Then the parts of the rod from which the material has been removed are coated (step 810). Any pre-formed processing is represented by "A" in Figure 10, and any post-coating processing is represented by "B" in Figure 10.

In step 610, polishing can be performed in any suitable manner. In some exemplary embodiments, a fine abrasive material is used to polish the protrusion 414 extending beyond the line 410 to completely or significantly remove the protrusion 414 to form a polished surface 702, as shown in FIG. 11 . Examples of polishing techniques include (but are not limited to) the use of abrasive wheels, scrubbing pads, sanding devices, fiber brushes, or deburring sheets.

In step 610, the composite rod is subjected to an operation such as mechanical buffing, which smoothes the part of the rod with outwardly protruding fibers. In the case of mechanical buffing, the buffing equipment usually travels along a continuous (oblique) channel formed by grinding the composite rod. In some exemplary embodiments, the polishing device is fixed while the composite rod moves relative to it. In some exemplary embodiments, the composite rod system is fixed while the polishing device moves relative to it.

In step 810, the coating can be performed in any suitable manner. In some exemplary embodiments, a coating composition is applied to the buffed surface 702 to form the coated surface 902, as shown in FIG. 11. The coating is applied to at least the buffed surface 702 to completely or significantly cover any remaining protrusions 414 that extend above the buffed surface 702. In addition, the coating can protect the polished surface 702 from abrasion during transportation and/or storage of the composite rib 1100, which may otherwise cause the fibers to protrude from the removed portion 406 again.

In step 810, the composite rod is subjected to an operation such as spraying, which covers the part of the rod having the polished surface 702. In some exemplary embodiments, the coating device is fixed while the composite rod moves relative to it. In the case of spraying, the coating equipment can travel along a continuous (oblique) channel formed by grinding the composite rod. Other coating techniques such as curtain coating and vacuum coating can also be used. In some exemplary embodiments, the coating device is fixed while the composite rod moves relative to it. In some exemplary embodiments, the composite rod system is fixed while the coating device moves relative to it. In some exemplary embodiments, only the removed portion 406 (such as the spiral channel 404) or some portions thereof are coated. In some exemplary embodiments, the removed portion 406 (such as the spiral channel 404) and the remaining portion 408 are coated.

The measured surface roughness of the removed part 406 after buffing and coating is greatly reduced compared with the surface roughness of the removed part 406 before buffing and coating.

A part of the resulting composite rib 1100 with a polished surface 702 and a coated surface 902 is shown in FIG. 11, which is a modified version of the detailed view of FIG. 5. Generally, the coating will be applied to all surfaces of the composite rod (or at least all surfaces from which the material has been removed), as shown in FIG. 11. Due to the polishing operation, the protrusion 414 (generated by the polishing operation) has been removed or reduced. As a result of the coating operation, any remaining protrusions 414 (produced by the grinding operation) have been completely or significantly covered. In other words, the surface smoothness of the spiral channel 404 is increased by the polishing and coating operations, which makes the composite rib 1100 safer/comfortable to handle.

The methods disclosed or suggested in other ways are implemented in continuous/online procedures, but these methods may be implemented in other ways. For example, the grinding process and the polishing process may form a first-level process, followed by the coating process and a curing process (which hardens the coating) as a (independent) second-level process.

It should be understood that the scope of these broad inventive concepts is not intended to be limited to the specific exemplary embodiments shown and described herein. Given the disclosure content, those familiar with the technology will not only understand the broad inventive concepts and their accompanying advantages, but will also discover various changes and modifications that can be seen in the objects disclosed in this article, including the related manufacturing methods. Method and system. For example, although various exemplary embodiments including a spiral channel formed in a composite rod are shown and described herein, these broad inventive concepts are in-depth and cover the removal of materials from the composite rod (e.g., each other Spaced discrete concentric grooves) and any type of anchor points formed in the rod. As another example, although the buffing and coating operations are shown and described herein as being applied to the side wall of a spiral channel of a composite rod, the buffing and/or coating operations can be applied to the spiral channel. Any surface where the fibers protrude to produce an undesirable rough surface. Therefore, it is sought to cover all such changes and modifications that fall within the spirit and scope of the broad concept of the invention described and claimed herein, and any equivalents thereof.

100: program 204: Spiral wrap 206: raised ribs 404: Spiral Channel 406: Remove part 408: remaining part 414: protruding part 702: Polished surface 902: Coated surface 102,104,302,304,610,810: steps 200, 400, 700, 900, 1100: composite ribs 202, 402: Composite ontology 300, 600, 800, 800, 1000: method 410,412: line A: Pre-formed processing B: Processing after coating, processing after grinding, processing after coating, processing after polishing D: depth T: thickness W, W': width

Figure 1 is an illustration of a conventional method of forming anchor points on the outer surface of a composite rib.

Fig. 2 is a side view of a part of a conventional composite rib produced by the method of Fig. 1.

3 is a diagram illustrating a method of forming an anchor point on the composite rib by removing material from the composite rib according to an exemplary embodiment.

Fig. 4 is a side view of a part of the composite rib produced by the method of Fig. 3.

Figure 5 is a detailed view of a part of the composite rib of Figure 4.

FIG. 6 is a diagram illustrating a method of forming an anchor point on the composite rib by removing material from the composite rib according to an exemplary embodiment.

Fig. 7 is a modified version of the detailed view of Fig. 5, showing a part of the composite rib produced by the method of Fig. 6.

FIG. 8 is a diagram illustrating a method of forming an anchor point on the composite rib by removing material from the composite rib according to an exemplary embodiment.

Fig. 9 is a modified version of the detailed view of Fig. 5, showing a part of the composite rib produced by the method of Fig. 8.

FIG. 10 is a diagram illustrating a method of forming an anchor point on the composite rib by removing material from the composite rib according to an exemplary embodiment.

Fig. 11 is a modified version of the detailed view of Fig. 5, showing a part of the composite rib produced by the method of Fig. 10.

300: method

302, 304: steps

A: Pre-formed processing

B: Processed after grinding

Claims (17)

A method of forming composite ribs, the method comprising: Forming a rod by combining a plurality of relatively parallel fibers with a resin, and the resin is cured to solidify the rod; and Grind the rod to remove the fibers and part of the resin. Such as the method of claim 1, wherein the fibers are glass fibers. The method of claim 1, wherein the resin is one of vinyl ester resin and epoxy resin. The method of claim 1, wherein the grinding system forms a continuous spiral groove in the rod. Such as the method of claim 4, wherein the spiral groove has a width in the range of .200 inches to .260 inches. Such as the method of claim 4, wherein the spiral groove has a depth in the range of 0.007 inch to 0.020 inch. Such as the method of claim 1, which further comprises polishing a surface of the spiral groove. The method of claim 1, further comprising coating a surface of the spiral groove. Such as the method of claim 1, which further comprises polishing a surface of the spiral groove, and After the buffing, the surface of the spiral groove is coated. A composite rib, which contains: A rod comprising a plurality of relatively parallel fibers joined by a cured resin, One of the continuous spiral grooves is formed along a length direction of the rod. Such as the composite rib of claim 10, wherein the fibers are glass fibers. Such as the composite rib of claim 10, wherein the resin is one of vinyl ester resin and epoxy resin. Such as the composite rib of claim 10, wherein the spiral groove has a width in the range of .200 inches to .260 inches. Such as the composite rib of claim 10, wherein the spiral groove has a depth in the range of 0.007 inch to 0.020 inch. Such as the composite rib of claim 10, wherein the spiral groove has a polished surface. Such as the composite rib of claim 10, wherein the spiral groove has a coated surface. Such as the composite rib of claim 10, wherein the spiral groove has a polished and coated surface.

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